Sevcon Troubleshooting
Page 2
Electrical Troubleshooting
Test Equipment Required:
• Digital multimeter (DMM) with diode test
function, FLUKE 79 model shown.
• Throttle Module Analyzer, Taylor-Dunn part
number 62-027-32
Definitions:
• Battery volts = full voltage available at the
batteries at the time of test.
• High: Greater than +4.5 volts
• Low: Less than +1.8 volts
Terminology used:
• The “HOT” side of a switch is the terminal
that the power is connected to.
• The “COLD” side of a switch is the terminal
that the power is switched to.
• FS-1 = Micro-switch in the accelerator
module.
DURING ALL TESTS
• After any repairs are made, completely retest
vehicle before lowering the drive wheels to
the ground.
Important Notes and Instructions
• This troubleshooting procedure is for the
Sevcon Power Pak and Micro Pak motor
speed controllers as equipped in standard
vehicles. Troubleshooting may not be valid
for vehicles equipped with special order
speed control options.
• For additional troubleshooting information,
use the handheld system anylizer part
number 62-027-61 or the computer system
anylizer (PCpaK) part number 62-027-63.
See note below.
• This troubleshooting guide assumes a
familiarity with the use of a digital multimeter
including, voltage tests, continuity tests, and
diode testing. If you are not familiar with
these types of tests then refer testing to a
qualified technician.
• These tests are not intended to locate a
problem on an incorrectly wired vehicle.
• Make sure the batteries are in good condition
and fully charged before performing any
tests.
• If the vehicle exhibits intermittent problems,
it must be in the failed mode for
troubleshooting. If it is running normally
when the testing is done then the problem
will not be identified.
• Some tests refer to a High/Low switch. The
High/Low switch is optional and the vehicle
may not be equipped with this option. If the
vehicle is without this option, there is a
jumper bypass installed in place of the switch
in the dash.
• All voltage tests are done referenced to
battery negative, unless otherwise specified.
• At the start of each test sequence you will
be instructed on how to place the control
switches. While testing, do not change the
position of any switches unless instructed
to do so.
Note: The PCpaK application is also capable of uploading
new controller parameters to the controller.
Controller parameter sets are available from Taylor-
Dunn. Individual parameters cannot be changed.
Turn the Key switch OFF then disconnect both
of the battery leads during any maintenance or
before disconnecting any electrical component
or wire. Failure to do so may cause severe bodily
injury and/or property damage.
The rear drive wheels may rotate during some
of the following tests. Block the front wheels,
raise the rear drive wheels off the ground, and
support the vehicle with jack stands. Failure to
do so may cause the vehicle to move and cause
property damage and/or serious bodily injury.
Turn the Key switch OFF BEFORE disconnecting
the batteries. Disconnecting the batteries with
the key switch ON may corrupt the controller
programming resulting in a fault code 1 (refer
to fault table).
This troubleshooting guide is written in
sequential order. All tests must be performed in
the order that they are written. Starting in the
middle or skipping sections when not instructed
to do so may lead to invalid test results.
Summary of Contents for B0-T48-48 Taylor Truck T48
Page 2: ......
Page 12: ...Model B 1 00...
Page 58: ...Maintenance Service and Repair Steering Page 14 Exploded View of Steering Gear...
Page 76: ...TAYLOR DUNN...
Page 94: ...TAYLOR DUNN...
Page 102: ...TAYLOR DUNN...
Page 116: ...TAYLOR DUNN...
Page 119: ...Sevcon Troubleshooting Page 3 Electrical Troubleshooting Identifying Your Controller...
Page 138: ...Sevcon Troubleshooting Page 22 Electrical Troubleshooting...
Page 158: ...Battery Charger Page 20 MN 402 000...
Page 161: ...Wire Diagrams Wire Diagrams Page 3...
Page 166: ...Illustrated Parts Parts Page 4 Front Brakes...
Page 168: ...Illustrated Parts Parts Page 6 Steering Linkage...
Page 170: ...Illustrated Parts Parts Page 8 Steering Column 1 2 3 4 5 6 7 9 8 12 10 11 13 14...
Page 172: ...Illustrated Parts Parts Page 10 Steering Gear 9 15 16 10 2 3 14 17 12 11 13 6 8 7 5 1 4...
Page 174: ...Illustrated Parts Parts Page 12 Front Suspension...
Page 176: ...Illustrated Parts Parts Page 14 Transmission Gear Case...
Page 178: ...Illustrated Parts Parts Page 16 Transmission Differential Case...
Page 182: ...Illustrated Parts Parts Page 20 Rear Brakes Brake Body...
Page 186: ...Illustrated Parts Parts Page 24 Motor...
Page 190: ...Illustrated Parts Parts Page 28 Master Cylinder 2 3 4 1 5 6 7 8...
Page 192: ...Illustrated Parts Parts Page 30 Brake Lines...
Page 194: ...Illustrated Parts Parts Page 32 Brake Linkage parking brake...
Page 196: ...Illustrated Parts Parts Page 34 Wheels and Tires Ref wheel hub 1 2 3...
Page 200: ...Illustrated Parts Parts Page 38 Speed Control Panel...
Page 202: ...Illustrated Parts Parts Page 40 Miscellaneous Frame and Body...
Page 210: ...Illustrated Parts Parts Page 48 Decals 1 2 4 3 5 6 7...
Page 212: ...Illustrated Parts Parts Page 50 Strobe Light...
Page 214: ...Illustrated Parts Parts Page 52 Steel Cab T48 Page 1...
Page 216: ...Illustrated Parts Parts Page 54 Steel Cab T48 Page 2...
Page 218: ...Illustrated Parts Parts Page 56 Tops T48...
Page 220: ...Illustrated Parts Parts Page 58 Doors T48...
Page 222: ...Illustrated Parts Parts Page 60 Optional Deckboards T48...
Page 224: ...Illustrated Parts Parts Page 62 Cargo Box...
Page 226: ...Illustrated Parts Parts Page 64 Stake Sides...
Page 230: ...Illustrated Parts Parts Page 68 3 4 5 6 1 2 Door Latch 9 8 7 Cab Components ET 3000...
Page 234: ...TAYLOR DUNN...